American Water Heater 71681 Water Heater User Manual

Index
Commercial Gas
Water Heater
Installation
Instructions and
Use & Care Guide
for models with prefix DCG and ADCG
To obtain technical, warranty or service assistance during
or after the installation of this water heater, call toll free:
1-800-456-9805
When calling for assistance, please have the following
information ready:
1. Model number
2. 7 digit product number
3. Serial number
4. Date of installation
5. Place of purchase
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2
71681 REV.A 03-09
what can happen if the instructions are not followed.
Table of Contents
Water Heater Safety . . . . . . . . . . . . .
Installation Instructions . . . . . . . . . . .
Unpacking the Water Heater .
Installation Requirements . . .
Site Location . . . . . . . . . . . . .
Clearances and Accessibility .
Combustion Air Supply and Ventilation
Water System Piping . . . . . . . . . . . . .
Gas Supply and Piping . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . .
Wiring Diagram . . . . . . . . . . . . . . . . .
Installation Checklist . . . . . . . . . . . . .
Operating Your Water Heater . . . . . . .
Maintenance of Your Water Heater . .
Trouble Shooting Chart . . . . . . . . . . .
Repair Parts Illustration . . . . . . . . . . .
2
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. 1-2
. 3-5
.3
..4
.4
.5
. 6-9
. 10-13
. 14-15
. 16
. 17
. 18
. 19
. 22-23
. 24-25
. 26
Index
INSTALLATION INSTRUCTIONS
Consumer Information
This water heater is design-certified by CSA
International as a Category I, non-direct vented water
heater which takes its combustion air either from the
installation area or from air ducted to the unit from the
outside.
This water heater must be installed according to all
local and state codes, or in the absence of local and
state codes, with the “National Fuel Gas Code”, ANSI
Z223.1(NFPA 54)- latest edition. Canadian installations
must be performed in accordance with CAN/
CSA-B149.1. This is available from the following:
American Gas Association
1515 Wilson Boulevard
Arlington, VA 22209
National Fire Protection Agency
1 Batterymarch Park
Quincy, MA 02269
Canadian Standards Association
5060 Spectrum Way
Mississauga, ON
L4W 5N6
Check the phone listings for the local authorities having
jurisdiction over this installation.
Installer and Owner Responsibilities
This manual has been prepared to acquaint you with
the installation, operation and maintenance of this gas
water heater and provide important safety information in
these areas.
Massachusetts code requires this water heater to be
installed in accordance with Massachusetts Plumbing
and Fuel Gas Code 248 CMR Sections 2.00 and 5.00.
A data plate identifying this water heater can be found
on the front of the water heater. When referring to this
water heater always have the information listed on the
data plate readily available.
Retain your original receipt as proof of purchase.
Unpacking the Water Heater
Excessive Weight Hazard
Use two or more people to move and
install water heater unless proper
handling equipment is utilized.
Failure to do so can result in back or
other injury.
Removing Packaging Materials
Important: Do not remove any permanent instructions,
labels, or the data label from outside of the water heater
or on the inside of panels.
• Remove exterior packaging and place
installation components aside.
• Inspect all parts for damage prior to installation
and start-up.
• Completely read all instructions before
attempting to assemble and install this product.
• After installation, dispose of packaging material
in the proper manner.
Read all of the instructions thoroughly before attempting
the installation or operation of this water heater. Keep
this manual for future reference.
Do not discard this manual. You or future users of this
water heater will need it for future reference.
The manufacturer and seller of this water heater will not
be liable for any damages, injuries or deaths caused by
failure to comply with the installation and operating
instructions outlined in this manual.
The manufacturer of this water heater recommends
that it be professionally installed by qualified
service technicians. Examples of qualified service
technicians include: those trained in the plumbing
and heating industry, local gas utility personnel or
an authorized service person.
3
Index
Site Location
•
•
FLAMMABLES
FLAMMABLE VAPORS
Vapors from flammable liquids will
explode and catch fire causing death or
severe burns.
Do not use or store flammable products
such as gasoline, solvents or adhesives
in the same room or area near the water
heater.
Keep flammable products:
1. far away from heater
2. in approved containers,
3. tightly closed and
4. out of children’s reach.
This water heater has a main burner and
an automatic ignition system. The ignition
system:
1. can come on at any time and
2. will ignite flammable vapors.
Vapors:
1. cannot be seen,
2. are heavier than air,
3. go a long way on the floor and
4. can be carried from other
rooms to the water heater by air
currents.
Do not install this water heater where
flammable products will be stored.
Installation Requirements
The water heater must be installed according to all local
and state codes, or in the absence of local and state
codes, the "National Fuel Gas Code”, ANSI Z223.1
(NFPA 54)-latest edition. Canadian installations must be
performed in accordance with CAN/CSA-B149.1.
4
Note: In the State of California, the water heater must
be braced, anchored, or strapped to avoid moving during an earthquake. Contact local utilities for code
requirements in your area or call 1-800-456-9805 and
request instructions.
•
•
•
Select a location near the center of the water
piping system. The water heater must be
installed indoors and in a vertical position on a
level surface. DO NOT install in bathrooms,
bedrooms, or any occupied room normally kept
closed.
Locate the water heater as close to the gas
vent as practical. Consider the vent system
piping and combustion air supply requirements
when selecting the water heater location. The
venting system must be able to run from the
water heater to termination with minimal length
and elbows.
Locate the water heater near the existing gas
piping. If installing a new gas line, locate the
water heater to minimize the pipe length and
elbows.
The water heater should be located in an area
not subject to freezing temperatures. Water
heaters located in unconditioned spaces (i.e.,
attics, basements, etc.) may require insulation
of the water piping and drain piping to protect
against freezing. The drain and controls must
be easily accessible for operation and service.
Maintain proper clearances as specified on the
data plate.
The operation of air-moving devices such as
exhaust fans, ventilation systems, clothes
dryers, fire-places, etc., can affect the proper
operation of the water heater. Note: Special
attention must be given to the location of these
devices and the conditions they may create.
Flow reversal of flue gases may cause an
increase of carbon monoxide inside of the
dwelling.
Important: Air for combustion and ventilation must not
come from a corrosive atmosphere. Any failure due to
corrosive elements in the atmosphere is excluded from
warranty coverage.
The following types of installation (but not limited to the
following) will require outdoor air for combustion due to
chemical exposure, and may reduce but not eliminate
the presence of corrosive chemicals in the air:
• Beauty shops
• Photo processing labs
• Buildings with indoor pools
• Water heaters installed in laundry, hobby or
craft rooms
• Water heaters installed near chemical storage
areas
Index
Important:
The water heater should be located in an area where
leakage of the tank or connections will not result in damage to the area adjacent to the water heater or to lower
floors of the structure. Due to the normal corrosive
action of the water, the tank will eventually leak after
an extended period of time. A suitable metal drain pan
should be installed under the water heater as shown
below, to help protect the property from damage which
may occur from leaks in the piping connections or tank.
The pan must limit the water level to a maximum depth of
1 3/4 inches (45mm) and be 2 inches (51mm) wider than
the water heater and piped to an adequate drain. The
pan must not restrict combustion airflow. Locate the
water heater near a suitable indoor drain. Outside drains
are subject to freezing temperatures which can obstruct
the drain line. The piping should be at least 3/4” (19mm)
ID and pitched for proper drainage. Under no circumstances will the manufacturer or seller of this water heater
be held liable for any water damage which is caused by
your failure to follow these instructions.
Figure1: Minimum Clearance Locations
Back
Sides
Top View
Front 24” min.
for service
Vent
Top to
ceiling
Pipe to
adequate
drain
1 3/4” Max
At least 2” greater than the
diameter of the water heater
Clearances and Accessibility
Notice: Minimum clearances from combustible
materials are stated on the data plate located on the
front of the water heater.
• If the water heater is installed in a restaurant
or food service location where the floor is
cleaned frequently, NSF International requires
the water heater to maintain 6 inches (150mm)
of clearance above the floor. To comply with the
NSF International requirement, install leg
extension kit. For availability contact
1-800-456-9805
• The water heater is certified for installation on a
combustible floor.
Important: If installing over carpeting, the carpeting
must be protected by a metal or wood panel beneath
the water heater. The protective panel must extend
beyond the full width and depth of the water heater by
at least 3 inches (76mm) in any direction, or if in an
alcove the entire floor must be covered by the panel.
The panel must be strong enough to carry the weight of
the water heater when full of water.
Figure 1 may be used as a reference guide to locate
the specific clearance locations. A minimum of 24
inches (610mm) of front clearance and 4 inches
(102mm) on each side should be provided for inspection
and service.
Sides
Front View
5
Index
COMBUSTION/VENT PIPE SYSTEM
Carbon Monoxide Hazard
Follow all instructions to locate and install
the vent pipe system.
Instructions can be found in this manual,
in state or local codes (or the authority
having jurisdiction), or in the absence of
such, the National Fuel Gas Code, ANSI
Z223.1, NFPA 54, Latest Edition. Canadian
installations must be performed in
accordance with CAN/CSA-B149.1
Failure to properly locate and install the
vent pipe system can result in death,
explosion, or carbon monoxide poisoning.
Combustion
Combustion air must be free of acid-forming chemicals.
These chemicals are found in aerosol sprays, detergents, bleaches, cleaning solvents, air freshener, paint
and varnish removers, refrigerant, and many other commercial products. When burned, vapors from these
products form highly corrosive acid compounds. These
products should not be stored or used near the water
heater or air inlet.
Venting
Vent pipe installation must be installed according to all
state and local codes, or in the absence of local and
state codes, the National Fuel Gas Code, NFPA 54,
ANSI Z223.1-latest edition. Canadian installations must
be performed in accordance with CAN/CSA-B149.1
It is the responsibility of the installing contractor to
provide a vent adequate in capacity and in good usable
condition. Btu/hr capacity limitations are governed by
the style and height of the vent/chimney. For installations in the United States, capacity tables are available
in the National Fuel Gas Code (ANSI Z223.1- latest edition). Canadian installation information can be found in
CAN/CSA-B149.1
U.L. recognized fuel gas and carbon monoxide (CO)
detectors are recommended in all applications and
should be installed using the manufacturer’s
instructions and local codes, rules, or regulations.
6
Important: Check to make sure the vent pipe is not
blocked in any way.
• Venting should be as direct as possible with a
minimum number of pipe fittings.
• Exhaust gas vents must be installed with U.L.
listed type B vent pipe according to the vent
manufacturer’s instructions and the terms of its
listing.
• Single wall vent connectors must have 6”
(152mm) of clearance from unprotected combustible surfaces.
• If sidewall venting is necessary, a power vent
kit is required. For availability contact 1-800456-9805.
• Vents that run through unconditioned spaces
where below freezing temperatures are expected should be properly insulated to prevent
freezing.
• Existing vent systems must be inspected for
obstructions, corrosion and proper installation.
• Vents must be connected to the water heater’s
drafthood by a certified vent connector or by
directly originating at the drafthood opening.
• Vertical gas vents must terminate with a listed
cap or other roof assembly and be installed
according to their manufacturer’s instructions.
• Horizontal vent connections must have an
upward slope of at least 1/4” (6mm) per
foot (305mm).
• Gas vents must be supported to prevent
damage, joint separation, and maintain
clearances to combustible materials.
• Vent connection joints should be fastened by
sheet metal screws or by other approved
methods.
• Vent and vent connectors should have
adequate support to keep weight off the
draft hood.
All pipe, fittings, and procedures must conform to
American National Standard Institute and American
Society for Testing and Materials (ANSI/ASTM) standards in the United States.
Important: If you lack the necessary skills required to
properly install this venting system, you should not
proceed, but get help from a qualified service
technician.
Index
Air Requirements
An adequate air supply shall be provided
for combustion and ventilation of this
water heater.
An insufficient supply can result in poor
combustion and possible sooting of the
burner, combustion chamber or flue
passageway. This may present a potential
fire hazard or could create a serious
health hazard by producing carbon
monoxide.
General
Where an exhaust fan or any other air consuming
appliance (Eg. Clothes dryer, furnace, etc.) is installed
in the same space as the water heater, sufficient air
openings must be available to provide fresh air when all
appliances are operating simultaneously.
The area in which the heater is located is classified as
either “an unconfined space” or “a confined space.”
An unconfined space is defined as a space having a
volume not less than 50 cubic feet per 1000 BTU/hour
(4.8 cubic meters per kilowatt) of combined input rating
of all appliances using the space. Adjacent open rooms
may be included as part of the unconfined space.
There shall be no closeable doors between these
rooms. An example of this is an open basement.
A confined space is one smaller than described above.
Air shall be supplied through permanent openings as
described in Figure 2. At no time shall an air opening
have a dimension of less than 3” (75 mm) and at no
time shall any top opening be lower than the top of the
water heater.
For buildings that are not well sealed (do not have tight
fitting doors and windows) natural air infiltration may
provide sufficient air required for combustion and ventilation. For buildings using tight construction (newer and
renovated structures), the air supply shall be introduced
from the outdoors, regardless of whether the space is
confined or unconfined.
Combustion Air “Supply” Ducts
Air supply ducts shall be of galvanized steel or equivalent corrosion resistant material. A single air duct may
not be substituted when required for upper and lower
air openings. Horizontal upper combustion air ducts
shall not slope downward toward the air inlet.
Louvers and Grills
Openings for air supply ducts must provide free unobstructed air movement. Louver and grill openings must
be sized to ensure that the FREE OPEN AREA is never
less than the area of the air duct.
LOCATION:
The location for top and bottom openings are as follows;
For U.S. installations:The top opening shall commence within 12” (300 m) of the top of space and the
bottom opening shall commence within 12” (300mm) of
the bottom of the enclosure.
For Canadian installations:The top opening shall be
located as close to the ceiling as practical but never
lower than the relief opening of the lowest draft control
device. The bottom opening shall be located neither
more than 18 inches (450 mm), nor less than 6 inches
(150 mm), above floor level.
7
Index
Air Opening Requirements
(a) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM
INSIDE THE BUILDING.
Two permanent openings (top and bottom) shall be provided connecting
the confined space (e.g., closet/small room) with the unconfined space.
Each opening shall have a free area of one square inch per 1,000
BTU/hour (22 cm²/kW) input of all appliances in the confined space, but
not less than 100 square inches (645 cm²).
b) BASEMENT INSTALLATION, EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM OUTDOORS.
Outside air inlets shall be a minimum of 12” (300mm) above the grade
(snow) line. When supplying air directly from the outdoors:
For American installations: Two openings (top and bottom) shall be
provided with each opening having a minimum free area of one square
inch per 4,000 BTU/hour input (5.5 cm²/kW) of total input rating of all
appliances in the confined space.
For Canadian installations: Canadian codes specify single air supply
source. Canadian customers and authorities having jurisdiction may use
the sizing listed in Table 1. When using a single air supply, the duct shall
terminate within 1 foot (300 mm) above and within 2 feet (600 mm) horizontally from the burner level of the appliance having the largest input.
Figure: 2 Equipment Location
and Combustion/Ventilation Air
Requirements
(a)
Permanent
Ventilation
Air
12” Grade
Table 1
Combined input of all Required Acceptable Equivalent duct
diameter
appliances in
free area of
confined space
duct
A1
B2
BTU/hr(kW)
in2(mm 2)
in(mm)
in(mm)
75,000(23)
100,000(30)
125,000(37)
150,000(45)
175,000(53)
200,000(60)
225,000(68)
250,000(75)
275,000(83)
300,000(90)
325,000(98)
350,000(105)
375,000(113)
400,000(120)
11(7,000)
14(9,000)
18(12,000)
22(14,000)
25(16,000)
29(19,000)
32(21,000)
36(23,000)
40(26,000)
43(28,000)
47(30,000)
50(32,000)
54(35,000)
58(37,000)
4(100)
4(100)
5(125)
5(125)
6(150)
6(150)
6(150)
7(175)
7(175)
7(175)
8(200)
8(200)
8(200)
9(225)
5(125)
5(125)
6(150)
6(150)
7(175)
7(175)
7(175)
8(200)
8(200)
8(200)
9(225)
9(225)
9(225)
10(250)
Combustion
Air Duct
12”
(b)
Venting
Outdoor
Air Ducts
Notes:
1.Maximum lenght of ducts in column A is 20 equivalent feet(6.1 meters).
2.Maximum lenght of ducts in column B is 50 equivalent feet(15.2 meters).
(c) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM
OUTDOORS.
For American installations: When supplying air directly from the outdoors using horizontal ducting, each opening shall have a free minimum
area of one square inch per 2,000 BTU/hour (11 cm²/kW) of total input
rating of all appliances in the confined space.
For Canadian installations: Refer to Table 1 of part (b).
(d) EQUIPMENT LOCATED IN CONFINED SPACES; ALL AIR FROM
OUTDOORS THROUGH VENTILATED ATTIC.
For American installations: When supplying air directly through vertical
ducting, each opening shall have a free minimum area of one square
inch per 4,000 BTU/hour (5.5 cm²/kW) of total input rating of all appliances in the confined space.
Combustion
(c)
Outlet Air
Inlet
Air Ducts
(d)
*U.S. installations require a dual duct system.
8
Index
Draft Hood/Damper Installation
Flue Outlet Reducer
Do not operate water heater with damper
in closed position, it must be in the open
position during water heater operation.
Do not negate the action of any existing
safety or operational controls.
Some units are shipped with a flue outlet reducer (See
Figure 3B). Use only the flue outlet reducer supplied
with this unit. The flue outlet reducer should be
connected to the top of the flue damper and sealed by
high temperature silicon.
The vent pipe must be installed according to all local
and state codes or, in the absence of local and state
codes, the “National Fuel Gas Code”, ANSI
Z223.1(NFPA 54)-latest edition.
Install the supplied draft hood and damper on the flue
outlet collar. Use only the supplied draft hood and
damper, DO NOT use any substitute or alter the
components in any way.
Place the damper on the water heater (see figure 3A).
Align the four pilot holes on top of the water heater with
the 4 corresponding holes on the damper bracket and
secure with the supplied screws. Next, align the draft
hood legs with the 4 corresponding pilot holes on top of
the water heater and attach securely with the supplied
screws. Locate the wiring from the ECO, and attach it to
the wiring harness on the damper (see Figure 3A).
Once damper is installed, ensure that the damper position indicator is visible (See figure 3A).
Figure 3B: Flue Outlet Reducer
Figure 3A: Flue Damper Assembly
Bracket screws
High
temperature
silicon sealant
Draft hood
Draft hood screws
Flue outlet reducer
Damper motor
Damper wiring harness
Damper in OPEN position
Damper motor
Damper wiring harness
ECO wiring harness
Damper position indicator
Damper motor
Damper wiring harness
Damper in OPEN position
9
9
Index
WATER SYSTEM PIPING
Piping Installation
10
Piping, fittings, and valves should be installed according to
the installation drawing (Figure 4). If the indoor installation
area is subject to freezing temperatures, the water piping
must be protected by insulation.
Water supply pressure should not exceed 80% of the working pressure of the water heater. The working pressure is
stated on the water heater’s data plate. If this occurs, a
pressure reducing valve with a bypass should be installed
in the cold water inlet line to the entire system. This should
be placed on the supply to the entire structure in order to
maintain equal hot and cold water pressures.
Note: Water supplied to the unit that exceeds 12 grains
(205 mg/l) total hardness may reduce the life and performance of the water heater. Depending on the degree of hardness, it is recommended that either a water pre-treatment
system or a water softener be installed and properly maintained.
Important: Heat cannot be applied to the water fittings on
the water heater as they may contain nonmetallic parts. If
solder connections are used, solder the pipe to the adapter
before attaching the adapter to the hot and cold water fittings.
1. The water heater may have three water piping connection points. The top and front are 1 1/2” NPT and the
connections on the back of some heaters are 2” NPT.
When using front or back connections a nipple inlet
tube combination is required. For availability contact
1-800-456-9805.
Note: Inlet and outlet piping connections cannot
be mixed. For example, a top inlet connection must
use a top outlet connection.
2. The installation of unions in both the hot and
cold water supply lines is recommended for
ease of removing the water heater for service or
replacement.
3. Since most commercial installations utilize higher
temperatures, the use of a tempering valve is
strongly recommended in all domestic hot water
lines (i.e. public restroom sinks, etc).
4. If installing the water heater in a closed water
system, install an expansion tank in the cold water
line as specified under “Closed System/Thermal
Expansion” (Page 12).
5. Install a shut-off valve in the cold water inlet line.
It should be located close to the water heater and
be easily accessible. Know the location of this
valve and how to shut off the water to the heater.
6. The water heater is shipped with a factory-installed
Temperature and Pressure Relief Valve. Install a
discharge line in the opening in the T & P valve
(see instructions on Page 13).
7. After piping has been properly connected to the
water heater, remove the aerator at the nearest hot
water faucet. Open the hot water faucet and allow
the tank to completely fill with water. To purge
the lines of any excess air, keep the hot water
faucet open for 3 minutes after a constant flow of
water is obtained. Close the faucet and check all
connections for leaks.
Space Heating
If this unit is to be used to supply both space heating and
domestic potable (drinking) water then the following
instructions must be followed:
1. All piping and components used must be suitable
for use with domestic (potable) drinking water.
2. Do not use piping or components that have been
connected to a nonpotable system or treated with
chromates or other toxic chemicals. Do not add any
chemicals to the water heater piping.
3. If system requires temperatures in excess of 120°F
(49°C) install a tempering valve, per the manufacturers
instructions, in the domestic (potable) hot water line
to limit the risk of scalding (See Figure 5).
4. Be sure to follow the manual(s) shipped with the
heating system. Also follow any state or local codes.
Figure: 4 Water Piping Installation
In a closed system use a
Thermal Expansion Tank
Cold Water
Supply to Fixtures
Main Water
Supply
Pressure Reducing
Valve with Bypass
Hot Water
Outlet
Unions
Cold Water
Inlet Valve
Temperature and
Pressure Relief Valve
Discharge line
6” max. above
drain
Drain line
3/4” ID min.
Metal drain
pan 1 3/4”
depth max.
Drain
Massachusetts:
Install a vacuum relief
in cold water line per
section 19MGL 142
Tempering Valve Installation
A Tempering Valve should be installed per the manufacturer’s instructions in the hot water line. See Figure 5
(below) for sample tempering valve installation.
Figure 5: Tempering Valve
Follow the tempering
valve manufacturer’s
instructions.
Cold
Water
Inlet
Hot
Water
Outlet
Tempered water
to fixtures
Tempering valve
(Set to 120°F)
Index
Figure 6: Commercial Unit with Auxiliary Booster Heater Two Temperature (With or Without Building Recirculation)
Outlet
Boosted
Temperature
Hot Water
to Fixtures
Thermometer
Shut-off valve
Thermometer
Shut-off valve
Temperature and
Pressure Relief Valve
Temperature and
Pressure Relief Valve
Check Valve
Typical
Booster
Heater
Pre-Heater
Thermal
Expansion
Tank
Shut-off valve
1 1/2” Cold
water supply
Shut-off valve
Pre-Heated
Water to
the Booster
Pressure
Reducing
Valve
Note: Install a vacuum
relief valve if required
by local codes.
Figure 7: Commercial Unit with Auxiliary Storage Heater - Forced Circulation With or Without
Building Recirculation - Front Inlet/Outlet Connections
Hot Water
Outlet
Thermometer
Shut-off valve
Storage Tank
Shut-off valve
Temperature and
Pressure Relief Valve
Thermal
Expansion
Tank
Heater
Temperature
and Pressure
Relief Valve
Pressure
Reducing
Valve
Shut-off valve
Plug
Cock
Check
Valve
Circulating
Pump
11
1 1/2” Cold
water supply
Note: Install a vacuum
relief valve if required
by local codes.
11
Index
Figure 8: Commercial Unit with Auxiliary Storage Heater - Forced Circulation
With or Without Building Recirculation - Top Inlet/Outlet Connections
Thermometer
Outlet
Boosted
Temperature
Thermometer
Thermal
Expansion
Tank
Hot Water
to Fixtures
Pre-Heated
Water to
the Booster
Pressure
Reducing
1 1/2” Cold
Valve
water supply
Shut-off valve
Check valve
Temperature and
Pressure Relief Valve
Typical
Booster
Heater
Shut-off
valve
Temperature and
Pressure Relief Valve
Pre-Heater
Note: Install a vacuum
relief valve if required
by local codes.
Please note the following:
DO NOT install this water heater with iron piping. The
system should be installed only with piping that is suitable for potable (drinkable) water such as copper,
CPVC, or polybutylene. DO NOT use PVC water piping.
DO NOT use any pumps, valves, or fittings that are not
compatible with potable water.
DO NOT use valves that may cause excessive restriction to water flow. Use full flow ball or gate valves only.
DO NOT use 50/50 tin-lead solder (or any lead based
solder) in potable water lines. Use 95/5 tin-antimony or
other equivalent material.
DO NOT tamper with the gas valve/thermostat, igniter,
or temperature and pressure relief valve. Tampering
voids all warranties. Only qualified service technicians
should service these components.
DO NOT use with piping that has been treated with
chromates, boiler seal, or other chemicals.
DO NOT add any chemicals to the system piping which
will contaminate the potable water supply.
12
Closed System/Thermal Expansion
Periodic discharge of the temperature and pressure
relief valve may be due to thermal expansion in a
closed water supply system. The water utility supply
meter may contain a check valve, backflow preventer or
water pressure reducing valve. This will create a closed
water system. During the heating cycle of the water
heater, the water expands causing pressure inside the
water heater to increase. This may cause the
temperature and pressure relief valve to discharge
small quantities of hot water. To prevent this, it is
recommended that a diaphragm-type expansion tank
(suitable for potable water) be installed on the cold
water supply line. The expansion tank must be properly
sized for the application. Contact the local water supplier or plumbing inspector for information on other methods to control this situation.
Important: Do not plug or remove the temperature
and pressure relief valve.
Index
Temperature and Pressure
Relief Valve
Explosion Hazard
If the temperature and pressure relief
valve is dripping or leaking, have a
qualified service technician replace it.
• Do not plug valve.
• Do not remove valve.
Failure to follow these instructions can
result in death or explosion.
Figure 9: T&P Relief Valve
must not exceed the working pressure of the water
heater as stated on the data plate.
Important: Only a new temperature and pressure relief
valve should be used with this water heater. Do not use
an old or existing valve as it may be damaged or not
adequate for the working pressure of the new water
heater. Do not place any valve or piping between the
relief valve and the tank.
The Temperature & Pressure Relief Valve:
• Must not be in contact with any electrical part.
• Must be connected to an adequate discharge
line.
• Must not be rated higher than the working
pressure shown on the data plate of the water
heater.
• The BTUH rating of the T & P valve must be
greater than, or equal to, the input rating of the
water heater.
The Discharge Line:
• Must not be smaller than the pipe size of the
relief valve or have any reducing coupling
installed in the discharge line.
• Must not be capped, blocked, plugged or
contain any valve between the relief valve and
the end of the discharge line.
• Must terminate a maximum of 6 inches (152mm)
above a floor drain or external to the building.
• Must be capable of withstanding 250°F (121°C)
without distortion.
• Must be installed to allow complete drainage of
both the valve and discharge line.
Index
For protection against excessive pressures and
temperatures, a temperature and pressure relief valve
must be installed in the opening marked “T & P RELIEF
VALVE” (See Figure 9). This valve must be design
certified by a nationally recognized testing laboratory
that maintains periodic inspection of the production of
listed equipment or materials as meeting the
requirements for Relief Valves and Automatic Shut-off
Devices for Hot Water Supply Systems, ANSI Z21.22.
(CSA4.4, Temperature, Pressure, Temperature and
Pressure Relief Valves and Vacuum Relief Valves in
Canada). The function of the temperature and pressure
relief valve is to discharge water in large quantities in
the event of excessive temperature or pressure developing in the water heater. The valve's relief pressure
13
13
Index
GAS SUPPLY AND PIPING
Explosion Hazard
Use a new AGA or CSA approved gas
supply line.
Install a shut-off valve.
Do not connect a natural gas water
heater to a L.P. gas supply.
Do not connect a L.P. gas water heater to
a natural gas supply.
Failure to follow these instructions can
result in death, explosion, or carbon
monoxide poisoning.
Gas Requirements
Read the data plate to be sure the water heater is
made for the type of gas being used. This information
will be found on the data plate located on the front of
the water heater. If the information does not agree with
the type of gas available, do not install or operate the
water heater. Call your dealer.
Note: An odorant may be added by the gas supplier to
the gas used by this water heater. This odorant may
fade over an extended period of time. Do not depend
upon this odorant as an indication of leaking gas.
Gas Piping
The gas piping must be installed according to all local
and state codes, or in absence of local and state codes,
with the “National Fuel Gas Code”, ANSI Z223.1 (NFPA
54)-latest edition. Canadian installations must be performed in accordance with CAN/CSA-B149.1.
Note: If using a flexible gas connector, make sure its
rating tag matches or exceeds the input of the water
heater.
Tables 2, 3A, and 3B on page 15 provide a sizing
reference for commonly used gas pipe materials.
Consult the “National Fuel Gas Code” or “Natural Gas
and Propane Installation Code” for the recommended
gas pipe size of other materials. Follow the instructions
below and reference Figure 10 for gas piping installation.
1. Install a readily accessible manual shut-off valve
in the gas supply line as recommended by the
local utility. Know the location of this valve and
14
how to turn off the gas to this unit.
2. Install a drip leg as shown. The drip leg must be no
less than 3 inches (76mm) long for the accumulation of dirt,foreign material and water droplets.
3. Install a ground joint union between the water
heater and the manual shut-off valve. This is to
allow easy servicing.
4. Turn the gas supply on and check for leaks. Use
a chloride-free soap and water solution (bubbles
forming indicate a leak) or other approved method.
Figure 10: Gas Piping
Manual Gas
Shut-off Valve
Ground
Joint
Union
Check with
local utility
for min. height
Drip leg
Gas Pressure
Important: The gas supply pressure must not exceed
the maximum supply pressure as stated on the water
heater’s data plate. Minimum supply pressure should
also be maintained per the data plate.
Index
Gas Pressure Testing
Important: This water heater and its gas connection
must be leak tested before placing the appliance in
operation.
• If the code requires the gas lines to be tested at
a pressure of 14” W.C. or greater, the water
heater and its manual shut-off valve must be
disconnected from the gas supply piping
system and the line capped.
• If the gas lines are to be tested at a pressure
less than 14” W.C., the water heater must
be isolated from the gas supply piping system
by closing its manual shut-off valve.
U.L. recognized fuel gas and carbon monoxide(CO)
detectors are recommended in all applications and
should be installed using the manufacturer’s instructions and local codes, rules, or regulations.
Note: Air may be present in the gas lines and could
prevent the burner from lighting on initial start-up. The
gas lines should be purged of air by a qualified service
technician after installation of the gas piping system.
15
Explosion Hazard
Have a qualified service technician make
sure L.P. gas pressure does not exceed
13” water column.
Failure to do so can result in death,
explosion, or fire.
15
Index
ELECTRICAL CONNECTIONS
Electrical Installation
If you lack the necessary skills required to properly
install the electrical wiring to this water heater, do not
proceed but have a qualified service technician perform
the installation.
When making the electrical connections, always make
sure:
• The voltage and frequency correspond to that
specified on the water heater data plate on the
front of the water heater.
• The electrical supply has the proper overload
fuse or breaker protection. The water heater
draws less than 7 amps.
• Wire sizes and connections comply with all
applicable codes.
• Wiring is enclosed in approved conduit
(if required by local codes).
• The water heater and electrical supply are
properly grounded.
• This water heater must be “hard-wired” do not
use an extension cord to supply electrical
power to this water heater.
Note: The wiring diagram can be found on page 17.
Always reference the wiring diagram(s) for the correct
electrical connections.
Caution: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper
and dangerous operation. Verify proper operation after
servicing.
16
1. Shut off the power at the electrical service box.
2. Loosen the screws securing the access panel to
the electrical compartment. (The electrical wiring
diagram can be found on the inside of the access
panel.) Set the access panel aside.
3. Connect the electrical supply to the water heater
in accordance with local utility requirements and
codes or, in the absence of local codes, with the
National Electrical Code, ANSI/NFPA 70 and/or the
CSA C22.1, Electrical Code. Use only a dedicated
electrical circuit containing a properly sized fuse or
circuit breaker. Maximum overload protection
should not exceed 15 Amperes.
4. Connect this circuit (directly from the electrical
service box) to an electrical disconnect switch.
5. Ground the water heater by connecting the
electrical service ground wire to the green ground
wire (provided).
Note: The power supply to this water heater must be
properly polarized, [120 volts from the hot lead (black)
to ground and 0 volts from the neutral lead (white) to
ground] otherwise, the unit will not operate.
6. After making all electrical connections, completely
fill the tank with water and check all connections for
leaks. Open the nearest hot water faucet and let it
run for 3 minutes to purge the water lines of air and
sediment and to ensure complete filling of the tank.
The electrical power may then be turned on.
Index
WIRING DIAGRAM
17
17
Index
INSTALLATION CHECKLIST
Water Heater Location Requirements
•
•
•
•
•
Centrally located with the water piping system.
Located as close to the gas piping and vent
pipe system as possible.
Located indoors and in a vertical position.
Protected from freezing temperatures.
Proper clearances from combustible surfaces
maintained and not installed directly on a
carpeted floor. Sufficient room to service the
water heater.
Provisions made to protect the area from water
damage. Properly sized drain pan installed and
piped to an adequate drain.
Installation area free of corrosive elements and
flammable materials.
Vent Pipe System
•
•
•
•
•
•
18
Draft hood and damper properly installed
Vent connectors securely fastened with screws
and supported properly to maintain 6” (152mm)
clearance.
Vent pipe and fittings of approved material.
Acceptable size, length, and number of elbows
on exhaust outlet pipe.
Installed in accordance with prevailing
provisions of local codes, or in the absence of
such, National Fuel Gas Code, NFPA 54, ANSI
Z223.1-Latest Edition. Canadian Installations
must be performed in accordance with
CAN/CSA-B149.1.
Drafthood or vent pipe should not be obstructed
in any way.
Vent Termination
Vertical
•
Vertical gas vents must terminate with a listed
cap or other roof assembly and be installed
according to their manufacturer’s instructions.
Water System Piping
•
•
•
•
•
Temperature and pressure relief valve properly
installed with a discharge line run to an open
drain and protected from freezing.
All piping properly installed and free of leaks.
Water heater completely filled with water.
A properly sized expansion tank must be
installed on all closed systems.
A tempering valve should be installed per
the manufacturer’s instructions.
Gas Supply and Piping
•
•
•
•
•
•
If using a flexible gas connector, make sure its
rating tag matches or exceeds the input of the
water heater.
Adequate pipe size and of approved material.
Gas supply is the same type as listed on the
water heater data plate.
Gas line equipped with full opening shut-off
valve, union and drip leg.
Approved pipe joint compound used.
Chloride-free soap and water solution or other
approved means used to check all connections
and fittings for possible gas leaks.
Electrical Connections
•
•
•
•
Unit must be “hard-wired” to a dedicated 120V
power supply
Proper polarity.
Water heater properly grounded.
Installed in accordance with prevailing
provisions of local codes, or in the absence of
such, National Electrical Code, ANSI/NFPA 70
and/or the CSA C22.1, Electrical Code.
Index
OPERATING YOUR WATER HEATER
Read and understand these directions thoroughly
before attempting to operate the water heater (see
Lighting Instructions on page 20). Check the data plate
on the front of the water heater for the correct gas. Do
not use this water heater with any gas other than the
one listed on the data plate. If you have any questions
or doubts, consult your gas supplier or gas utility company.
L.P. (Propane) Models
Propane gas is heavier than air and in the occurrence
of a leak in the system, the gas will settle on the floor
level. Basements, crawl spaces, skirted areas under
mobile homes (even when ventilated), closets and
areas below ground level will serve as pockets for the
accumulation of gas. Before lighting a propane gas
water heater, smell all around the appliance at floor
level. If you smell gas, follow the instructions as given
in the warning on the front page.
When your propane tank runs out of fuel, turn off the
gas at all gas appliances including pilot lights. After the
tank is refilled, all appliances must be re-lit according to
their manufacturer’s instructions.
Water Heater Operation
When the thermostat calls for heat, it will signal the
damper to open. Once the damper fully opens, it will
signal the igniter to light the pilot. The pilot will then
ignite the main burners. The water heater will operate
until the call for heat ends. At this time the main
burners and pilot will shut-off and the damper will close.
See Figure 12 below for a sequence of operation
flowchart.
Figure 12: Sequence of Operation
ELECTRICAL POWER
APPLIED TO UNIT
THERMOSTAT CALLS
FOR HEAT
DAMPER OPENS
PILOT IGNITES
WATER HEATER
OPERATES TILL CALL
FOR HEAT ENDS
THERMOSTAT
SATISFIES
BURNER & PILOT
SHUT OFF
DAMPER CLOSES
PILOT IGNITES
BURNER
19
19
Index
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on this
label.
2. Turn off all electric power to the appliance.
3. Set the thermostat to the lowest setting.
4. This appliance is equipped with an ignition device
which automatically lights the pilot. Do not try to
light the pilot by hand.
5. Turn the gas control knob clockwise
to the
“OFF” position. Do not force.
6. Wait ten (10) minutes to clear any
gas. If you then smell gas, STOP!
Follow “B” in the safety information
above on this label. If you don’t
smell gas , go to the next step.
7. Turn gas control knob counterclockwise
8. Set thermostat to desired setting.
9. Turn on all electric power to the
appliance.
to “ON”.
10.If the appliance will not operate after three automatic
tries, follow these instructions once more. If the
appliance still refuses to light, follow the instructions "To Turn Off Gas To Appliance" and call a qualified service technician.
TO TURN OFF GAS TO APPLIANCE
1.Turn off all electric power to the appliance if service is
to be performed.
2.Set the thermostat to lowest setting.
Stacking
Stacking occurs when a series of short draws of hot
water are taken from the water heater tank. This causes
increased cycling of the burner and can result in
increased water temperatures at the hot water outlet. A
tempering valve should be installed in the hot water
supply line to reduce the risk of scald injury.
Water Temperature Regulation
Water temperature over 125°F can cause
severe burns instantly or death from
scalds.
Children, disabled and elderly are at
highest risk of being scalded.
Feel water before bathing or showering.
Temperature limiting valves are
recommended.
20
3.Turn the gas control knob clockwise
position. Do not force.
to the off
The thermostat is adjusted to its lowest temperature
setting when it is shipped from the factory. Water temperature can be regulated by moving the temperature
dial to the preferred setting. The preferred starting
point is 120°F(49°C).
Important: Since most commercial installations utilize
higher temperatures, the use of a tempering valve is
strongly recommended in all domestic hot water lines
(i.e. public restroom sinks, etc). Auxiliary commercial
equipment (i.e. dishwashers, laundry equipment, etc.)
may require higher temperature settings. Refer to
instruction manuals supplied with this type equipment
for recommended temperature settings.
Important: Adjusting the thermostat past the 120°F
(49°C) setting on the temperature dial (see Figure 13)
will increase the risk of scald injury. Hot water can produce first degree burns within:
Figure 13: Temperature Dial
120°F (49°C) more than 5 minutes
130°F (54°C) at 20 seconds
140°F (60°C) at 3 seconds
150°F (66°C) at 1-1/2 seconds
160°F (71°C) at less than 1 second
Each water heater consists of a mechanical temperature stop set to 140°F (60°C). To set to a different setting remove the temperature dial knob, loosen the shaft
nut and re-position the mechanical temperature stop.
Tighten the shaft nut and replace the temperature dial
knob.
Index
Emergency Shut Down
Important: If overheating occurs or the gas supply fails
to shut off, close the manual gas supply valve and turn
the gas control knob to the off position. Turn off the
electrical supply to the unit and close the cold water
supply valve. Do not operate the water heater again
until it has been thoroughly checked by a qualified
service technician.
Checking the Draft
Burn Hazard
Do not touch vent.
Doing so can result in
burns.
After successfully lighting the water heater, allow the
unit to operate for 15 minutes and check the drafthood
relief opening for proper draft. Pass a match flame
around the relief opening of the drafthood (See Figure
14). A steady flame drawn into the opening indicates
proper draft. If the flame flutters or is blown out,
combustion products are escaping from the relief
opening. If this occurs, do not operate the water heater
until proper adjustments or repairs are made to the vent
pipe system.
Figure 14: Vent Draft Test
Operational Conditions
Condensation
Moisture from the products of combustion condenses
on the tank surface and the outside jacket of the water
heater and forms drops of water which may fall onto the
burner or other hot surfaces. This will produce a “sizzling” or “frying” noise. This condensation is normal
and should not be confused with a leaking tank.
Condensation may increase or decrease at different
times of the year.
High efficient energy saver water heaters will produce
larger amounts of condensation on initial start up or
when a large amount of hot water is being used. Do
not confuse this with a “tank leak”. Once the water
reaches a temperature of 120°F (49°C) and the tank
warms up (usually 1-2 hours), the condensation will
stop.
Important: It is always recommended that a suitable
drain pan be installed under the water heater to protect
the area from water damage resulting from normal
condensation production, a leaking tank or piping
connections. Under no circumstances is the manufacturer to be held responsible for any water damage in
connection with this water heater.
Water Heater Sounds
During the normal operation of the water heater sounds
or noises may be heard. These noises are common and
may result from the following:
1. Normal expansion and contraction of metal parts
during periods of heat-up and cool-down.
2. Condensation causes sizzling and popping within
the burner area and should be considered normal.
3. Sediment buildup in the tank bottom will create
varying amounts of noise and may cause
premature tank failure. Drain and flush the tank
as directed under “Draining and Flushing”.
Smoke/Odor
Burner Flames
Inspect the burner flames through the viewport and
compare them to the drawings in Figure 15. A properly
operating burner should produce a soft blue flame and
be about 2”(51mm) to 2 -1/2”(64mm) in height. Blue tips
with yellow inner cones are satisfactory. The tips of the
flame may have a slight yellow tint. The flame should
not be all yellow or have a sharp blue-orange color.
Contaminated air may cause an orange colored flame.
Contact a qualified service technician if the flame is not
satisfactory.
The water heater may give off a small amount of smoke
and odor during the initial start-up of the unit. This is
due to the burning off of oil from metal parts of a new
unit and will disappear after a few minutes of operation.
Safety Shut-off
This water heater is designed to automatically shut-off
in the event of the following:
1. The pilot flame is extinguished for any reason.
2. The water temperature exceeds 205°F (96°C).
Figure 15: Pilot/Burner Flame
2 - 2 1/2”
21
21
Index
MAINTENANCE OF YOUR WATER HEATER
Draining and Flushing
It is recommended that the tank be drained and flushed
every 6 months to remove sediment which may buildup
during operation. Note: Warranty is null and void in the
event lime & scale deposits are allowed to exceed two
inches in depth.
The water heater should be drained if being shut down
during freezing temperatures. To drain the tank, perform the
following steps:
1. Turn off the gas to the water heater at the
manual gas shut-off valve and turn off electricity.
2. Close the cold water inlet valve.
3. Open a nearby hot water faucet.
4. Connect a hose to the drain valve and
terminate it to an adequate drain.
Note: The drain hose should be rated for at least 200°F
(49°C). If the drain hose does not have this rating, open the
cold water inlet valve and a nearby hot faucet until the
water is no longer hot.
5. Open the water heater drain valve and allow all
the water to drain from the tank.
6. Remove the screws holding the cleanout
plate, then remove the plate for access.
7. Remove any lime, sediment, or scale from the
tank. Be careful not to damage the glass lining.
8. Flush the tank with water as needed to remove
any remaining sediment.
9. Check gasket on cleanout plate, replace if
necessary.
10. Replace the cleanout plate and screws, tighten
sufficiently.
11. Close the drain valve, refill the tank, and restart
the water heater as directed under “Operating Your
Water Heater”.
If the water heater is going to be shut down for an extended period, the drain valve should be left open.
Important: Condensation may occur when refilling the
tank and should not be confused with a tank leak.
Routine Preventative
Maintenance
22
At least annually, a visual inspection should be made of the
venting and air supply system, piping systems, main burner,
and pilot burner. Check the water heater for the following:
• Obstructions, damage, or deterioration in the
venting system. Make sure the ventilation and
combustion air supplies are not obstructed.
• Build-up of soot and carbon on the main burner
and pilot burner. Check for a soft blue flame.
• Leaking or damaged water and gas piping.
• Presence of flammable or corrosive materials in
the installation area.
• Presence of combustible materials near the
water heater.
• Verify proper operation after servicing this water
heater
Important: If you lack the necessary skills required to properly perform this visual inspection, you should not proceed,
but get help from a qualified service technician.
Temperature and Pressure
Relief Valve
Explosion Hazard
If the temperature and pressure relief
valve is dripping or leaking, have a
qualified service technician replace it.
• Do not plug valve.
• Do not remove valve.
Failure to follow these instructions can
result in death or explosion.
Manually operate the temperature and pressure relief
valve at least once a year to make sure it is working properly (See Figure 16). To prevent water damage, the valve
must be properly connected to a discharge line which terminates at an adequate drain. Standing clear of the outlet
(discharged water may be hot), slowly lift and release the
lever handle on the temperature and pressure relief valve
to allow the valve to operate freely and return to its closed
position. If the valve fails to completely reset and continues to release water, immediately shut off the manual gas
valve, electric power and the cold water inlet valve and
call a qualified service technician.
Figure 16: T&P Valve Test
Index
Pilot Burner and Main
Burner Assembly Inspection
To access the pilot burner and main burner for inspection:
1. Turn off gas at main shutoff valve and turn off
electrical power.
2. Disconnect the gas supply line from the gas valve.
3. Remove the 2 screws holding the Pilot & Main
Burner Assembly in place. See Figure 17 for
location of screws.
Figure 17: Pilot/Burner Assembly Removal
6. When replacing the gas valve, use an approved
Teflon® or pipe joint compound on the pipe threads.
7. Screw the new gas valve onto the burner assembly.
8. Reconnect the pilot tube to the gas valve.
9. Reconnect the main gas line to the gas valve.
10. Turn the gas supply on and check for leaks. Use a
chlorine-free soap and water solution (bubbles
forming indicate a leak) or other approved method.
11. Reconnect the 4 wires to their proper location and
restore electrical power to the unit.
11. Verify proper operation after servicing this water
heater.
12. If additional information is required, contact the
Product Service and Support Group at 1-800-4569805.
Anode Rod Inspection
4. Carefully slide the assembly out of the water heater.
5. If needed, use a brush or vacuum to clean any soot
or debris from the burners.
6. Check for correct alignment of burners before
sliding assembly back into the water heater.
7. Carefully slide Pilot/Burner Assembly back into the
water heater.
8. Replace and sufficiently tighten the two screws
holding the Pilot/Burner Assembly in place.
9. Reconnect the gas supply line to the gas valve.
10. Turn on gas at main shutoff valve.
11. Check for gas leaks and proper operation on the
unit after servicing.
Gas Valve Removal and
Replacement
It is recommended that this maintenance be performed
by a qualified service technician.
1. Turn the thermostat to its lowest setting.
2. Turn off gas at manual gas shut-off valve
(see figure 10 for reference) and disconnect
electrical power from water heater.
2. Unplug the 4 wires located on the gas valve. Label
wire position for correct reattachment.
3. Disconnect pilot tube from the gas valve.
4. Disconnect the main gas line from the gas valve.
Use care not to crack the gas valve housing.
5. Carefully unscrew the gas valve from the burner
assembly.
Important: When removing gas control valve do not
use a pipe wrench or vise to grip the body.
23
Each water heater contains at least one anode rod,
which will slowly deplete while protecting the glass-lined
tank from corrosion and prolonging the life of the water
heater. Certain water conditions will cause a reaction
between the rods and the water. Once the anodes are
depleted, the tank will start to corrode, eventually
developing a leak. The most common complaint associated with the anode rod is a "rotten egg smell" produced from the presence of hydrogen sulfide gas dissolved in the water. Do not remove this rod permanently
as it will void any warranties, stated or implied. A special anode is available for this complaint. This rod may
reduce but not eliminate water odor problems. The
water supply system may require special filtration
equipment from a water conditioning company to successfully eliminate all water odor problems.
Artificially softened water is exceedingly corrosive
because the process substitutes sodium ions for magnesium and calcium ions. The use of a water softener
may decrease the life of the water heater tank.
The anode rods should be removed from the water
heater tank every 3 years for inspection. If the rods are
more than 50% depleted, the anode rods should be
replaced.
In replacing the anodes:
1. Turn off gas supply and electrical power to the
water heater.
2. Shut off the water supply and open a nearby
hot water faucet to depressurize the water tank.
3. Drain approximately 5 gallons (19 l) of water
from tank (Refer to “Draining and Flushing” for
proper procedures). Close drain valve.
4. Remove old anode rods.
5. Use Teflon® tape or approved pipe sealant on
threads and install new anode rods.
6. Turn on water supply and open nearby hot
water faucet to purge air from water system.
7. Restart the water heater as directed under
“Operating Your Water Heater.” See the "Repair
Parts Illustration" for anode rod location.
23
Index
DCG3 SERIES
COMMERCIAL GAS DAMPERED WATER HEATERS
High water temp.
YES
Will ECO light
reset once temp.
in tank cools? NO
No Hot Water
NO
Repair
power
problem
YES
Replace
gas
valve
Power to
heater?
Is ECO light on?
YES
Check for 24V
between PV &
PV/MV terminals
on gas valve
NO
When thermostat NO
is turned up
does pilot spark?
YES
NO
Does pilot light?
YES
Does sparking
stop?
Replace
ICM
Check gas supply
YES
NO
Clean flame
sensor - check
ground. If still
problem,
see below
Check for 24V
between PV &
PV/MV terminals
ignition control
module (ICM)
NO
YES
OK
YES
Bad spark
assembly or
wiring between
spark assembly
& ICM
Does main
burner fire?
Repair
gas
supply
Replace
Check continuity
across ECO
ECO
OPEN
Go to
thermostat
troubleshooting
flow chart
YES
NO
NO
Is there 24V
NO
between MV &
PV/MV terminals
at gas valve?
Is there 24V
NO
between MV &
PV/MV terminals
at the ICM?
YES
Check for
blockage in
burner or orifice, NO
also check
incoming gas
supply
Does
main burner
stay lit until
thermostat
satisfies?
NO
Does pilot light
shrink or go out
when main
burner fires?
NO
YES
Is gas flex being
used, or other
small pipe?
NO
Replace
ICM
Check &
adjust gas
pressure
Replace
gas
valve
FCG3-0805
Go to
thermostat
troubleshooting
flow chart
Check for 24V
Is ground good
between purple NO
NO
from control
and white wires
module
to
on the ignition
incoming ground?
control module
(ICM)
YES
Repair
YES
Ground
Check for 24V
NO
between PV &
Check for 24V
MV/PV terminals
between orange YES
ignition control
& white wires on
module (ICM)
damper harness
Replace
YES
NO
ICM
Bypass
damper,
Check spark wire
orange & purple
for damage &
wires, if heater
FOUND continuity. Also ALL
fires then
DAMAGE
OK
check spark
replace
assembly for
damper
cracks in ceramic
or wrong spark
gap
Go to
thermostat
Replace
Replace
troubleshooting
ICM
faulty
flow chart
component
YES
ALL
SHOULD
BE OK
CLOSED
Copyright© by American Water Heater Company 2005. All rights reserved.
OK
Index
DCG3 SERIES
THERMOSTAT TROUBLESHOOTING FLOW CHART
No voltage or
low voltage from
purple wire
between
thermostat board
& ECO board
Replace
bad
sensor(s)
With an ohm meter
set at X1, check
NO
orange wires on
set pot. (3,000 ohms
at lowest setting and
0 ohms at highest
setting)
Replace
set pot
When slowly turning
set pot dial from low
HAS
to high, ohm reading
BAD SPOT should be a smooth
transition with no
skips, jumps or
glitches
Replace
ECO board
Check ECO
and ICM
NO
Will ECO board
reset?
YES
NO
Is ECO light on?
YES
Check orange wire
from ECO board to
damper for 24V
YES
YES
Check purple wire
from thermostat
for 24V
NO
Check
damper
High water
temperature
Temp.
0°C
10°C
20°C
30°C
40°C
50°C
60°C
70°C
80°C
90°C
40°F
50°F
70°F
90°F
100°F
120°F
140°F
160°F
180°F
190°F
200°F
FCG3-0805
NO
OK
OHMS
READING
NO GOOD
Take ohm reading
from upper sensor
and lowest sensor and
compare reading with
chart below.
(A temperature
reading from a water
sample taken from
T&P valve is also
needed for this test)
OHMS OK
0
32648
19898
12492
8057
5327
3602
2488
1752
1256
916
26109
19906
11884
7333
5827
3758
2488
1688
1170
982
828
1
31026
18968
11942
7722
5117
3468
2400
1693
1216
888
25400
19383
11592
7165
5697
3679
2439
1656
1150
965
814
Sensor Resistance vs. Temperature
Resistance (K ohms)
2
3
4
5
6
29495 28049 26682 25389 24166
18088 17253 16461 15710 14998
11419 10922 10450 10000
9572
7403
7099
6808
8532
6268
4917
4726
4543
4368
4201
3340
3217
3099
2986
2878
2316
2235
2157
2083
2011
1637
1582
1530
1480
1432
1177
1140
1105
1070
1037
861
835
810
786
763
24712 24045 23399 22771 22163
18876 18383 17905 17440 16990
11308 11032 10763 10502 10248
7000
6839
6683
6531
6383
5570
5446
5326
5208
5094
3602
3527
3453
3382
3312
2391
2344
2298
2253
2209
1625
1595
1566
1537
1509
1129
1110
1090
1071
1053
949
933
917
901
886
801
788
775
762
749
7
23010
14322
9165
6016
4042
2774
1942
1385
1005
741
21573
16553
10000
6238
4982
3244
2166
1481
1035
871
737
Copyright© by American Water Heater Company 2005. All rights reserved.
8
21915
13680
8778
5775
3889
2675
1876
1340
974
719
21000
16128
9760
6098
4873
3177
2124
1454
1017
857
725
9
20879
13071
8409
5546
3742
2579
1813
1297
944
698
20445
15715
9526
5961
4767
3112
2083
1427
999
842
713
Replace
thermostat
circuit
board
Index
REPAIR PARTS ILLUSTRATION
When ordering repair parts always give the following
information:
1. Model, serial, and product number
2. Type of gas
3. Item number
4. Parts description
Repair Parts List
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
26
Part Name and Description
Drafthood
Diptube (Top)
Diptube (Front) (Optional not pictured)
Diptube (Back) (Optional not pictured)
Flue Baffles
Clean Out Gasket
Clean Out Cover
Clean Out Cover Jacket
Drain Valve
Main Burner Tube(s)
Burner Tray
Pilot Burner Assembly
Main Burner Manifold
Gas Valve
No.
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Part Name and Description
Main Burner Orifice(s)
Control Box Cover
Transformer
Ignition Control Module
Thermostat board
ECO Reset Board
Control Box
Wiring Harness
Anode Rod(s)
T&P Valve
Temp. Control Potentiometer
Upper Temperature Sensor/ECO
Lower Temperature Sensor
Flue Damper